Process For Manufacturing Liquid And Solid Organic Fertilizer From Animal Manure

ABSTRACT

Processes for manufacturing organic fertilizer products, such as liquid and solid organic fertilizer, from animal manure are disclosed, together with the fertilizer products produced therefrom.

CROSS-REFERENCE TO RELATED APPLICATIONS

Continuation of U.S. application Ser. No. 15/628,878 filed Jun. 21,2017, which is a Continuation of U.S. application Ser. No. 14/623,602,filed Feb. 17, 2015, issued Jun. 27, 2017 as U.S. Pat. No. 9,688,584,claiming benefit of the filing date of U.S. Provisional Application Ser.No. 61/940,563, filed Feb. 17, 2014, and U.S. Provisional ApplicationSer. No. 62/026,188, filed Jul. 18, 2014, the entire contents of each ofwhich is incorporated by reference herein.

BACKGROUND Technical Field

The present disclosure relates to organic fertilizer products andprocesses for manufacturing such products.

Technical Background

Fertilizer products can generally comprise organic or inorganicmaterials of natural or synthetic origin that can supply one or moreessential nutrients to plants. In varying proportions, fertilizerproducts can generally provide one or more primary nutrients, such as,for example, nitrogen (N), phosphorus (P), and potassium (K); optionallyone or more secondary nutrients, such as, for example, calcium (Ca),magnesium (Mg), and sulfur (S); and optionally one or moremicronutrients, such as, for example, boron (B), chlorine (Cl), copper(Cu), iron (Fe), manganese (Mn), molybdenum (Mb), zinc (Zn), and nickel(Ni).

Primary and secondary nutrients can be consumed by plants in largequantities, and can be present in plant tissues at levels ranging from0.15 wt. % to 6 wt. % on a dry matter basis (i.e., 0% moisture).Micronutrients can be consumed in smaller quantities, and can be presentin plant tissues at part per million levels, for example, from about0.15 ppm to about 400 ppm on a dry matter basis.

Other micronutrients required by plants, such as carbon, hydrogen, andoxygen can be supplied via water, such as rainfall or irrigation, andcarbon dioxide from the atmosphere.

Organic fertilizer products have been known to improve biodiversity(i.e., soil life) and long term productivity of soils, and may alsoprovide large repositories for carbon dioxide. Organic nutrients canincrease the abundance of soil organisms by providing organic matter andmicronutrients, such as, for example, mycorrhizae (i.e., fungi that canaid plants in absorbing nutrients), and can significantly reduce theneed for pesticide applications.

Conventional organic fertilizers, such as, for example, unprocessedchicken manure, worm castings, compost, seaweed, and naturally occurringmineral deposits are typically solid materials, which limits their usedue to labor and equipment costs and regulatory restrictions.

In addition, while the use of organic fertilizer products are increasingdue to a desire for environmentally friendly materials, mostconventional organic fertilizer products contain lower quantities ofnutrients and require extended periods of time to breakdown into usefulsoil materials.

Thus, there is a need for improved organic fertilizer products that canprovide desirable quantities of nutrients to plants and soils, withoutthe additional labor and equipment costs and regulatory restrictionsassociated with conventional organic fertilizer products. These needsand other needs are satisfied by the processes and products of thepresent disclosure.

SUMMARY

In accordance with the purpose(s) of the invention, as embodied andbroadly described herein, this disclosure, in one aspect, relates toprocesses for the manufacture of liquid and solid organic fertilizerproducts.

In one aspect, the present disclosure provides a process formanufacturing an organic fertilizer product, the process comprising:providing an animal waste composition comprising an animal waste,contacting the animal waste composition with an acid to produce astabilized animal waste composition, aerating the animal wastecomposition, and separating a solid component and a liquid component ofthe stabilized animal waste composition.

In a second aspect, the present disclosure provides a process asdescribed above, wherein aerobic conditions are maintained throughoutthe process.

In a third aspect, the present disclosure provides a process asdescribed above, further comprising subjecting the separated liquidcomponent to an autothermal thermophilic aerobic bioreaction.

In a fourth aspect, the present disclosure provides a process asdescribed above, wherein the autothermal thermophilic aerobicbioreaction comprises maintaining aerobic condition and a temperaturesuitable for the promotion of thermophilic bacteria for a period oftime.

In a fifth aspect, the present disclosure provides an organic fertilizerproduct prepared from the methods described herein.

In a sixth aspect, the present disclosure provides an organic fertilizerfree from or substantially free from pathogens.

BRIEF DESCRIPTION OF THE FIGURES

The accompanying figures, which are incorporated in and constitute apart of this specification, illustrate several aspects and together withthe description serve to explain the principles of the invention.

FIG. 1 is a schematic of an exemplary process for manufacturing organicfertilizer products from animal manure, in accordance with variousaspects of the present invention.

FIG. 2 is a schematic of an alternative exemplary process formanufacturing organic fertilizer products from animal manure, inaccordance with various aspects of the present invention.

FIG. 3 is a schematic of an exemplary integrated facility for convertinganimal manure into liquid and solid organic fertilizer products.

Additional aspects of the invention will be set forth in part in thedescription and figures which follow, and in part will be obvious fromthe description, or can be learned by practice of the invention. Theadvantages of the invention will be realized and attained by means ofthe elements and combinations particularly pointed out in the appendedclaims. It is to be understood that both the foregoing generaldescription and the following detailed description are exemplary andexplanatory only and are not restrictive of the invention, as claimed.

DESCRIPTION

The present invention can be understood more readily by reference to thefollowing detailed description of the invention.

Before the present compounds, compositions, articles, systems, devices,and/or methods are disclosed and described, it is to be understood thatthey are not limited to specific synthetic methods unless otherwisespecified, or to particular reagents unless otherwise specified, as suchcan, of course, vary. It is also to be understood that the terminologyused herein is for the purpose of describing particular aspects only andis not intended to be limiting. Although any methods and materialssimilar or equivalent to those described herein can be used in thepractice or testing of the present invention, example methods andmaterials are now described.

Definitions

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. Although any methods andmaterials similar or equivalent to those described herein can be used inthe practice or testing of the present invention, example methods andmaterials are now described.

As used in the specification and the appended claims, the singular forms“a,” “an” and “the” include plural referents unless the context clearlydictates otherwise. Thus, for example, reference to “a solvent” includesmixtures of two or more solvents.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, another aspect includes from the one particular value and/orto the other particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint. It is also understood that there are a number of valuesdisclosed herein, and that each value is also herein disclosed as“about” that particular value in addition to the value itself. Forexample, if the value “10” is disclosed, then “about 10” is alsodisclosed. It is also understood that each unit between two particularunits are also disclosed. For example, if 10 and 15 are disclosed, then11, 12, 13, and 14 are also disclosed.

As used herein, the terms “optional” or “optionally” means that thesubsequently described event or circumstance can or cannot occur, andthat the description includes instances where said event or circumstanceoccurs and instances where it does not.

Disclosed are the components to be used to prepare the compositions ofthe invention as well as the compositions themselves to be used withinthe methods disclosed herein. These and other materials are disclosedherein, and it is understood that when combinations, subsets,interactions, groups, etc. of these materials are disclosed that whilespecific reference of each various individual and collectivecombinations and permutation of these compounds cannot be explicitlydisclosed, each is specifically contemplated and described herein. Forexample, if a particular compound is disclosed and discussed and anumber of modifications that can be made to a number of moleculesincluding the compounds are discussed, specifically contemplated is eachand every combination and permutation of the compound and themodifications that are possible unless specifically indicated to thecontrary. Thus, if a class of molecules A, B, and C are disclosed aswell as a class of molecules D, E, and F and an example of a combinationmolecule, A-D is disclosed, then even if each is not individuallyrecited each is individually and collectively contemplated meaningcombinations, A-E, A-F, B-D, B-E, B—F, C-D, C-E, and C—F are considereddisclosed. Likewise, any subset or combination of these is alsodisclosed. Thus, for example, the sub-group of A-E, B-F, and C-E wouldbe considered disclosed. This concept applies to all aspects of thisapplication including, but not limited to, steps in methods of makingand using the compositions of the invention. Thus, if there are avariety of additional steps that can be performed it is understood thateach of these additional steps can be performed with any specificembodiment or combination of embodiments of the methods of theinvention.

Each of the materials disclosed herein are either commercially availableand/or the methods for the production thereof are known to those ofskill in the art. Each of the tanks, vessels, transfer lines, pumps,valves, etc. recited herein are commercially available or can befabricated by those of ordinary skill in the art. Moreover, such tanks,vessels, and the like, can be made of any material, such as, forexample, stainless steel, suitable for use in handling the waste,chemicals, and environmental conditions described herein.

It is understood that the compositions disclosed herein have certainfunctions.

Disclosed herein are certain structural requirements for performing thedisclosed functions, and it is understood that there are a variety ofstructures that can perform the same function that are related to thedisclosed structures, and that these structures will typically achievethe same result.

As used herein, the term “buffer solution” is intended to refer to anaqueous solution comprising a weak acid and a weak base. A buffersolution is intended to minimize or prevent changes in the pH of asolution or mixture. The pH of a buffered solution (i.e., a solution ormixture comprising a buffer solution) does not change or changes verylittle upon addition of a small amount of a strong acid or base.

As used herein, the term “colloid” is intended to refer to a microscopicdispersion of a substance throughout another substance. In one aspect,particles having a diameter of from about 1 micrometer to about 1,000micrometers can be dispersed in another substance, such as a solution.

As used herein, the term “thixotropic” is intended to refer to a shearthinning property.

As used herein, the term “sterilization” is intended to refer to a heattreatment process that eliminates, renders inert, or inactivatespathogens, including transmissible agents such as fungi, bacteria,viruses, spore forms, etc. present on a surface or contained in a fluid.Sterilization is not intended to imply the elimination of all forms oflife.

As used herein, the term “thermal stabilization” is intended to refer toa process that eliminates or reduces the population of bacteria thatcause anaerobic decomposition of organic matter.

As used herein, the term “organic” is intended to refer to a naturalsource, for example, of a starting material. While not intended to belimiting, a starting material for an organic fertilizer can compriseplant and/or animal byproducts, rock powder, seaweed, inoculants,conditioners, dairy product waste, livestock manure, liquid manure, wormcastings, peat, guano, compost, blood meal, bone meal, fish meal,decomposing crop residue, cheese whey, mixed liquor from food and/orlivestock processing facilities, wastewater from food processingoperations, and any combination thereof. In another aspect, anynaturally sourced material that can provide nitrogen, phosphate, and/orpotash can be, for example, a starting material for an organicfertilizer product.

As used herein, the term “animal waste” or “animal manure solids” isintended to refer to manure solids that are present in a composition oran animal waste slurry that contains manure. Solids content refers tothe amount of solids present in a composition that remain after waterhas been removed or allowed to evaporate. In one aspect, “animal waste”can refer to chicken manure. In other aspects, “animal waste” can referto waste from other animals, such as, for example, hogs, turkey, orother animals not specifically recited herein. In yet another aspect,“animal waste” can refer to a mixture of waste products from two or moretypes of animals.

As used herein, the term “chicken manure” is intended to refer tochicken excreta that can be used as a fertilizer.

As used herein, the term “layered manure” is intended to refer to anunadulterated waste product from egg laying chickens.

As used herein, the term “hydrolyzed feather meal” is intended to referto a product made from poultry feathers by partially hydrolyzing thefeathers under elevated heat and pressure. In one aspect, a hydrolyzedfeather meal can optionally be further processed prior to introductioninto a manure manufacturing process or incorporation with organicfertilizer products, as described herein.

As used herein, the terms “poultry litter” and “broiler litter” areintended to refer to material used as bedding in poultry operations to,for example, ease the handling of manure. Conventional poultry litterand broiler litter can comprise wood shavings, sawdust, peanut hulls,shredded sugar cane, straw, and/or other absorbent, low-cost, organicmaterials.

As used herein, the term “manure slurry” is intended to refer to amixture of manure and any liquid, e.g., urine and/or water. Thus, in oneaspect, a manure slurry can be formed when animal manure and urine arecontacted, or when manure is mixed with water from an external source.No specific moisture and/or solids content is intended to be implied bythe term slurry.

As used herein, the term “aerobic decomposition” is intended to refer tothe decomposition of organic matter in the presence of oxygen. In oneaspect, aerobic decomposition is intended to refer to an aerobicdecomposition process that proceeds at a rate greater than a comparablenaturally occurring decomposition.

Conventional Fertilizer Products

Fertilizers products are available in various forms. The most typicalform of fertilizer products is solid fertilizer in granulated orpowdered form. The next most common form of fertilizer product is liquidfertilizer. In various aspects, liquid fertilizer products can beadvantageous as they can provide more immediate effects, wide coverage,and are relatively easy to use compared to solid fertilizer products.

Other fertilizer products can be designed to slowly release one or morenutrients. Such slow release fertilizer products, such as fertilizerspikes, tablets, etc, can reduce the burning effect resulting fromapplication of large amounts of nitrogen. Other slow-release fertilizerproducts can comprise polymer coatings to provide a time-release effector staged release of nutrients.

With the increased desirability of environmentally friendly products,organic fertilizer products are becoming more popular. Conventionalorganic fertilizer products have lower nutrient levels and break downslowly into complex organic structures (e.g., humus), which can improvesoil structure and the ability to retain moisture and nutrients. Organicnutrients can also increase the abundance of soil organisms by providingorganic matter and micronutrients for such organisms. Organic fertilizerproducts can also improve the biodiversity (i.e., soil life) and longterm productivity of a soil, and can provide large repositories forstorage of carbon dioxide, but use of these organic fertilizer productscan be limited by higher labor and equipment costs and regulatoryrestrictions.

Animal Waste

Poultry and other livestock are commonly reared in facilities that aredesigned to manage manure and liquid waste generated by such animals.For example, poultry are typically raised on beds of litter that containa filler such as wood shavings, wood chips and/or saw dust, spilledfood, feathers, and manure. After a growout on the bed of litter andduring successive growouts, the litter is predominantly manure, and iseventually replaced with fresh bedding.

In addition to livestock production, farmers raise poultry for theproduction of eggs. Through industry advances, farmers now raise theseanimals in cages in buildings reaching as high as six stories. The largeamount of manure produced is often accumulated and stored in outdoorholding areas.

Farmers manage the manure and liquid waste from livestock rearingfacilities in several ways. For example, many farmers apply the manureand liquid waste onto agricultural fields. Other farmers spread themanure and liquid waste from the facilities directly onto their land.

Manure excreted by poultry and other livestock typically contains avariety of pathogens, including Salmonella, Coliform, Fecal Coliform,Soil Transmitted Helminths (hookworm, Ascaris, and whipworm),Campylobacter, Avian Influenza, Histoplasma, Capsulatum Fungus, andEscherichia coli. The presence of these pathogens poses health risks tofarm workers handling the manure. In addition, the use or distributionof manure containing these pathogens on agricultural crops can posehealth and environmental concerns to farm workers and consumers.

In various aspects, the methods of the present disclosure can utilizeand/or treat animal manure from a variety of animals, such as, forexample, poultry. In one aspect, the animal waste stream to be treatedcan comprise poultry manure. In other aspects, the waste stream cancomprise animal waste, feces, urine, food, bedding materials, such aswood chips and/or sawdust, feathers, and other materials. In anotheraspect, a poultry litter can contain one or more harmful microorganisms,such as bacteria, viruses, protozoa, and/or other parasites orpathogens.

Animal waste can be provided from an on-site facility or can bedelivered, for example, in bulk quantities by truck. It should also beunderstood that the properties, for example, the nutrient content andphysical properties of a given animal waste product can vary dependingupon, for example, the type of animal and/or rearing or growth facility,length of time the animal waste has been stored, environmentalconditions, etc. In one aspect, properties, such as, for example,nitrogen content, phosphorus content, potassium content, calciumcontent, sulfur content, boron content, magnesium content, molybdenumcontent, sodium content, manganese content, zinc content, iron content,copper content, moisture, and pH, can vary depending upon the type ofanimal and/or rearing or growth facility. For example, poultry litteranimal waste can contain woodchips, sawdust, feathers, and/or othermaterials in addition to feces, and the moisture content can varydepending upon whether the litter originated in a broiler or egg-layingfacility. Poultry litter can comprises a variety of materials of varyingsize.

The conventional methods to handle manure and liquid waste products frompoultry and livestock production facilities do not address the healthand environmental concerns described herein. Thus, the abundance ofanimal manure, such as chicken manure, and the problems associated withits disposal led to the development of a new process for manufacturingorganic liquid and solid fertilizers by aerobic decomposition of animalmanure, as described herein.

Aerobic bacteria (“aerobes”) are important decomposers and are veryabundant in animal manure, such as, for example, chicken manure. In oneaspect, a gram of soil or decaying organic matter can comprise millionsof aerobic bacteria. Aerobic bacteria are the most nutritionally diverseof all organisms and can eat nearly anything. Aerobic bacteria utilizecarbon as a source of energy and nitrogen to build protein, so that theycan grow and reproduce. Aerobic bacteria obtain energy by oxidizingorganic material, especially the carbon fractions. While bacteria caneat a wide variety of organic compounds, they can have difficultyescaping unfavorable environments due to their size and lack ofcomplexity. Changes in oxygen, moisture, temperature, or acidity canresult in inactivity or death. Aerobic bacteria typically need oxygenlevels greater than 5% in air to survive.

In one aspect, aerobic bacteria are preferred for the present inventiondue to the fact that they can rapidly and effectively decompose organicmatter. Aerobic bacteria can also excrete desirable nutrients such asnitrogen, phosphorus, and magnesium. When oxygen levels fall below 5% inair, aerobes begin to die and decomposition can slow by as much as 90%.At this point, anaerobic micro-organisms take over and, in the process,produce significant quantities of useless organic acids and amines(ammonia like substances), along with other noxious compounds such ashydrogen sulfide, cadaverine, and putrescine. These compounds can bemalodorous and can contain unavailable nitrogen compounds. In someaspects, the products of anaerobic bacteria can be toxic to certainplant species. Thus, it is desirable to minimize or prevent the growthof anaerobic bacteria during the decomposition process. Anaerobicmetabolism can produce low molecular weight organic acids, such as, forexample, propionic, acetic, and butyric acid. These acids can bephytotoxic to plants. Anaerobic fertilizer products typically requiremonths to cure and get rid of these compounds. In other aspects, otheranaerobic decomposition byproducts can inhibit seed germination and rootelongation in certain plant species.

In one aspect, different types of bacteria can aid in aerobicdecomposition, depending upon, for example, the temperature of theenvironment and/or organic matter being decomposed. For example,psychrophilic bacteria work in the lowest temperature range, are mostactive at about 13° C., and will work up to about 21° C., wheremesophilic bacteria begin to take over. Mesophilic bacteria can rapidlydecompose organic matter, producing acids, carbon dioxide and heat.Mesophilic bacteria have an effective working temperature range of fromabout 21° C. to about 37° C. Above approximately 37° C., mesophilicbacteria begin to die off, and are replaced by heat-loving thermophilicbacteria which thrive at temperatures ranging from about 57° C. to about71° C. Thermophilic bacteria consume significant quantities ofdegradable materials and as a result, cannot sustain their populationfor an extended period of time. As the population of thermophilicbacteria decline and the temperature of the organic matter cools,mesophilic bacteria again become active and can consume any remainingorganic material, together with the assistance of other microorganisms.In general, temperatures above about 60° C. are needed to killnon-desirable organisms like pathogens and the seeds of weed species. Attemperatures above about 71° C., organic materials can become sterileand lose disease fighting properties.

The methods of the present disclosure can be effective for treating anyanimal manure, and especially poultry manure and livestock manure. Inone aspect, the animal manure can be present as a liquid slurry. In afurther aspect, the disclosed methods can be effective for treating anutrient-rich animal manure that can be useful for producing fertilizer.Non-limiting examples of animals commonly reared in such operationsinclude sheep, swine, poultry, goats, cattle, dairy cows, ducks, geese,and rabbits. In a still further aspect, the invention is especiallyapplicable to poultry rearing, swine rearing, and dairy cow rearingoperations.

In another aspect, the organic fertilizer products prepared by themethod of the present disclosure can, when applied to a soil, provideone or more of the following: nourish the soil in a natural manner,provide a balanced release (i.e., slow and fast release) of nutrients,establish improved water retention of the soil, improve soil porosity,deliver deeper root penetration of nutrients, or a combination thereof.

In another aspect, the methods described herein do not result in theloss of nitrogen and/or phosphorus in an animal waste material. Theresulting organic liquid fertilizer products can be useful as, forexample, a fertilizer spray or additive into other products. Similarly,the solid organic fertilizer products can be spread onto fields orcrops, or can be incorporated into other agricultural compositions. In afurther aspect, the resulting organic fertilizer products of the presentinvention can be useful in lawn and garden markets. In still furtheraspects, the products can be used in turf management applications. Instill further aspects, products produced by the disclosed methods can beretail packaged for use by consumers. In an even further aspect, theproducts can be used in professional activities, for example, inhorticulture-related activities.

In one aspect, the methods of the present disclosures are directed tothe production of organic fertilizers from animal manure. In variousaspects, the methods of the present disclosure can provide liquidorganic fertilizer products and/or solid organic fertilizer products. Inanother aspect, solid organic fertilizer products produced by themethods of the present disclosure can have a moisture content of lessthan about 12 wt. %.

Method for Treating Animal Manure

As briefly described above, the present disclosure relates to methodsfor treating animal manure and waste products from, for example, poultryand livestock production facilities. In one aspect, the methods of thepresent disclosure can comprise contacting animal manure with atreatment composition. In another aspect, the waste product can comprisepoultry manure and contaminated bedding materials. In still anotheraspect, the methods described herein can at least partially detoxifyanimal feces or a composition comprising animal feces. In yet anotheraspect, the methods can utilize organic materials and can produce anutrient rich liquid and/or solid organic product that can be useful asfertilizer. In still another aspect, the methods described herein canprovide a nutrient rich liquid and/or solid organic fertilizer productthat is free from or substantially free from pathogens. In one aspect,an organic fertilizer product prepared from the methods of the presentdisclosure can be free from or substantially free from pathogens, asdetermined by one or more of the following test procedures: UnitedStates Environmental Protection Agency (EPA) 1682 “Salmonella in SewageSludge (Biosolids) by Modified Semisolid Rappaport-Vassiliadis (MSRV)Medium; EPA 1681 “Fecal Coliforms in Sewage Sludge (Biosolids) byMultiple-Tube Fermentation using A-1 medium; United States Food and DrugAdministration (FDA) Bacteriological Analytical Manual (BAM), 8^(th)edition, chapter 4; polymerase chain reaction assay via BAXTM; or acombination thereof.

In one aspect, the methods and apparatus described herein can be used asa stationary system, for example, wherein animal waste materials can betransported from a rearing or growth facility. In another aspect, themethods and apparatus described herein can be used as a mobile system,for example, that can be temporarily located at a rearing or growthfacility to treat animal waste, and then can subsequently be moved toanother location. In one aspect, an animal manure can be provided inbulk form, for example, from a truck equipped with a transfer screw. Inother aspects, the methods described herein or any portion thereof canbe performed in a continuous, semi-continuous, or batch process.

In various aspects, the disclosed methods can convert animal manure,through a series processes, into a solid and/or a liquid fertilizer. Ina further aspect, fertilizer produced by the disclosed methods can meetthe requirements for organic fertilizer. In a yet further aspect, thedisclosed methods can be used for many types of animal waste. In aspecific aspect, the disclosed methods are particularly useful forchicken manure, including dry manure and liquids, for example, frombroiler chicken and egg-laying chicken facilities, respectively. Asdescribed above, animal waste can be utilized from an on-site facilityor can be provided in bulk, for example, by truck or a conveyor system.

While not intended to be limiting, the composition of an exemplarychicken manure, prior to treatment, is detailed in Table 1, below.

TABLE 1 Composition of Exemplary Chicken Manure Raw Chicken ManureNUTRIENTS Analysis Nitrogen Total Nitrogen % 2.05 Organic Nitrogen %0.66 Ammonium Nitrogen % 1.387 Nitrate Nitrogen % <0.01 Major andSecondary Nutrients Phosphorus % 0.86 Phosphorus as P2O5 % 1.97Potassium % 1.04 Potassium as K2O % 1.25 Sulfur % 0.22 Calcium % 3.34Magnesium % 0.28 Sodium % 0.16 Micronutrients Zinc ppm 198 Iron ppm 668Manganese ppm 140 Copper ppm <20 Boron ppm 30 Other Properties Moisture% 70.18 Total Solids % 29.82 C:N Ratio 4.5:1 Total Carbon % 9.1 Chloride% 0.31 pH 8.30

It should be understood that the treatment methods described herein cancomprise multiple individual steps, and that unless recited otherwise,the steps can be performed in any order. It should also be understoodthat multiple individual steps can be combined into a single step, andthat certain steps are optional, depending upon, for example, the animalwaste product to be treated and the desired properties of the resultingproduct. In other aspects, the order of individual treatment steps canaffect the outcome of the process and in such aspects, the treatmentsteps can be performed in the order described in any of the aspectsrecited herein or illustrated in the embodiments in the accompanyingfigures.

In one aspect, an animal waste product can have a moisture content offrom about 20% to about 80% or higher, by weight. In various aspects,the moisture content can be adjusted to a level of at least about 75%,by weight, for example, about 75%, 77%, 79%, 81%, 83%, 85%, 87%, 89%, orhigher. In other aspects, the moisture content can be adjusted to alevel of at least about 80%, by weight, for example, at least about 80%,82%, 84%, 86%, 88%, 90%, 92%, 94%, 96%, or higher; or to a level of fromabout 80% to about 85% by weight. It should be understood that themoisture content of an animal waste product or a slurry thereof canvary, depending upon type and age of animal, together with storage andenvironmental conditions.

In one aspect, the moisture content can be adjusted, if needed, at thisor any subsequent step of the process, using water and/or a nutrientenriched liquid. In one aspect, use of a nutrient enriched liquid canminimize and/or eliminate dilution of one or more desirable nutrientsthat can be present in the animal waste. Exemplary nutrients can includethose compounds beneficial for fertilizer or agricultural applications,such as, nitrogen, phosphorus, and potassium. In one aspect, a nutrientenriched liquid can be water derived from the treatment methodsdescribed herein, for example, water that has been in contact withanimal waste. In another aspect, a nutrient enriched liquid can beseparately prepared using animal waste or desirable chemical compounds.In one aspect, the nutrient enriched liquid is prepared from watercontacted with animal waste and does not introduce non-organiccomponents into the treatment process. The proportions of nutrientenriched liquid and water, for example, clean or municipal water, usedin the treatment process can vary, depending upon the particular animalwaste product being treated and/or the desired properties of theresulting treated product, and one of skill in the art could readilydetermine an appropriate proportion of nutrient enriched liquid andwater to be used. In various aspects, the proportion can range from 100%water to 100% nutrient enriched liquid, and the present invention isintended to include all combinations there between.

The pH of an animal waste product can vary, depending upon the type ofanimal, storage and/or environmental conditions, other materials presentin the waste, or other factors. In various aspects, an animal wasteproduct, for example, a poultry litter, can have a pH of from about 7.8to about 8.8. In one aspect, the pH of an animal waste can be adjusted,for example, to a neutral and/or slightly acidic value. In one aspect,the pH of an animal waste product or a slurry containing animal wastecan be measured to determine what, if any, adjustment is needed. One ofskill in the art could readily determine the pH of an animal wasteproduct and determine the degree of adjustment to be made. While notwishing to be bound by theory, it is believed that such an adjustmentcan neutralize any basic compounds present in the animal waste andprevent the formation and/or release of ammonia from nitrogen compoundspresent in the waste. In various aspects, the pH can be adjusted to avalue of from about 3 to about 7, for example, about 3, 3.5, 4, 4.5, 5,5.5, 6, 6.5, or 7; from about 4 to about 7, for example, about 4, 4.5,5, 5.5, 6, 6.5, or 7; from about 4.5 to about 7, for example, about 4.5,5, 5.5, 6, 6.5, or 7; from about 5 to about 7, for example, about 5,5.2, 5.4, 5.6, 5.8, 6, 6.2, 6.4, 6.6, 6.8, or 7; from about 5.5 to about7, for example about 5.5, 5.6, 5.7, 5.8, 5.9, 6, 6.1, 6.2, 6.3, 6.4,6.5. 6.6, 6.7, 6.8, 6.9, or 7; or from about 6 to about 7, for exampleabout 6, 6.1, 6.2, 6.3, 6.4, 6.5. 6.6, 6.7, 6.8, 6.9, or 7. It should beunderstood that the pH can be less than 6 or greater than 7, and theinventive methods are not intended to be limited to any particular pHvalue. In another aspect, an animal waste having a pH less than about 6or greater than about 7 can be treated as described herein. In yetanother aspect, an animal waste having a pH of from about 6 to about 7can be treated as described herein, and can maintain all orsubstantially all of the nitrogen and/or other nutrients present in thewaste as delivered and minimize and/or prevent the loss of nitrogen fromthe formation and release of ammonia.

In another aspect, if an animal waste product, as delivered, has a pH offrom about 6 to about 7, a reduced or no adjustment may be needed.

A pH adjustment, if needed, can be performed using any suitable pHadjusting agent. In one aspect, any acidic compound can be appliedand/or contacted with all or a portion of the animal waste product. Inanother aspect, an acid can be contacted with all or a portion of theanimal waste product. Exemplary acids that can be utilized to adjust thepH of an animal waste can comprise citric acid, acetic acid, phosphoricacid, carbonic acid, hydrochloric acid, nitric acid, sulfuric acid, or acombination thereof. In a specific aspect, citric acid can be used. Inanother aspect, an acid derived from natural sources can be used. In yetanother aspect, an acid that can be classified as an organic product canbe used. Any pH adjusting agent, such as, for example, an acid, can becontacted as a solid or a liquid. In one aspect, a solution, forexample, an aqueous solution of citric acid can be contacted with ananimal waste product. In another aspect, a solid, for example, citricacid powder, can be contacted with an animal waste product. In yet otheraspects, the animal waste product can first be contacted with a liquid,such as, for example, water, to dilute the animal waste and facilitateimproved contact with an acid or solution thereof. In one aspect, ananimal manure can be contacted, for example, sprayed, with an aqueouscitric acid solution to lower the pH to a desirable value and to curtailvolatilization of ammonia containing compounds. Any suitable form and/orconcentration of a pH adjusting agent can be utilized, and one of skillin the art could readily determine an appropriate pH adjusting agent,concentration, and method of delivery for a particular animal wasteproduct. In one aspect, an aqueous 50 wt. % solution of citric acid canbe contacted with the animal manure or diluted slurry thereof. Themixture of acid and animal manure can be mixed, for example, by stirringor agitation, for a period of time ranging from, for example, about 5minutes to about 60 minutes. In various aspects, the use of citric acidcan produce ammonium citrate, a stable product that sequesters the freeammonia previously present in the animal manure.

In yet another aspect, a slurry of animal manure can be contacted withsteam to maintain a slurry temperature of from about 30° C. to about 70°C., from about 50° C. to about 70° C., or from about 60° C. to about 70°C. In other aspects, a slurry can be aerated without the addition ofsteam. In one aspect, steam is used to adjust the temperature of the pHadjusted animal manure or slurry thereof to a value of from about 30° C.to about 35° C., such that mesophilic bacteria can begin to decomposeorganic matter. In other aspects, the temperature of a slurry can beadjusted via other traditional means, for example, external or immersionheaters, instead of using steam.

The animal waste product, either prior to, during, or subsequent to anypH adjustment, if needed, can optionally be moved, for example,conveyed, to a tank or vessel for subsequent processing. In one aspect,the diluted and stabilized (i.e., pH adjusted) slurry of animal manurecan be transferred from one vessel to another vessel using, for example,a cavity pump. Cavity pumps are commercially available and arewell-suited to moving slurries containing materials such as stones,feathers, wood chips, etc. A transfer line containing the slurry canoptionally be directed to a vibratory screen, for example, vibrating ina vertical axial mode or in a horizontal cross mode, having appropriatesized holes to ensure that materials larger than about 0.125 inches canbe excluded from the slurry stream.

In other aspects, an animal waste product, after pH adjustment, can beaerated to remove odorous compounds and to maintain an aerobicenvironment. In one aspect, a slurry of diluted and stabilized (i.e., pHadjusted) animal manure, such as, for example, chicken manure, can beplaced in a vessel and aerated by sparging the slurry with air. Inanother aspect, the pH of a slurry comprising a diluted and stabilizedanimal manure can be maintained at a level of from about 3 to about 7,from about 5 to about 6, or at any of the pH ranges described above withrespect to treatment with an acid, during aeration. In various aspects,the duration of an aeration step can vary, provided that aerobicconditions are maintained throughout the process.

In one aspect, during and/or subsequent to aeration, the slurrycontaining animal manure can be heated via injection of steam to atemperature of from about 50° C. to about 80° C., or from about 60° C.to about 70° C. In one aspect, water can be added, if needed, to adjustor maintain the moisture content of the slurry to a level of from about80 wt. % to about 98 wt. % water; from about 85 wt. % to about 98 wt. %;or from about 90 wt. % to about 98 wt. %. In another aspect, water canbe added, if needed, to adjust or maintain the moisture content of theslurry to a level of at least about 80 wt. %, at least about 85 wt. %,at least about 90 wt. %, at least about 92 wt. %, at least about 94 wt.%, at least about 96 wt. %, or at least about 98 wt. %. In yet anotheraspect, the moisture content can be adjusted or maintained such thataerobic conditions are maintained in the slurry.

Once a desired moisture or liquid level has been obtained, for example,via addition of water and/or nutrient enriched liquid, the resultingaqueous mixture can optionally be allowed to remain in contact for aperiod of time to facilitate the breakdown of organic matter in themanure. In one aspect, the aqueous mixture can be allowed to stand for aperiod of time without mixing. In another aspect, the aqueous mixturecan be mixed, for example, via stirring, shaking, or other suitablemeans, for a period of time. In another aspect, the aqueous mixture canbe aerated or sparged with air during all or a portion of a period oftime. In another aspect, aerobic conditions are maintained aremaintained during the entire period of time so as to prevent the growthof anaerobic bacteria. It should be noted that, even when aerobicconditions are maintained, it is possible to have small and/or localizedconcentrations of anaerobic bacteria remaining present in a sample. Thepresent invention is not intended to require that no anaerobic bacteriaare present, but rather that aerobic conditions are maintained thatfoster and promote the growth of aerobic bacteria. In another aspect,aeration of the animal manure containing slurry can continue for aperiod of time from about 2 hours to about 48 hours, for example, about2, 3, 4, 5, 6, 8, 10, 12, 14, 16, 18, 20, 24, 28, 32, 36, 40, 44, or 48hours. In other aspects, the slurry can be aerated for a period of timeless than about 2 hours or greater than about 48 hours, and the presentinvention is not intended to be limited to any particular time periodfor aeration. In another aspect, the slurry can be aerated for a periodof time up to about 4 hours.

In one aspect, the resulting slurry after aeration and optional contactwith steam can be subjected to a sterilization step to kill pathogenspresent in the slurry. In one aspect, an aerated, stabilized slurry canbe used as an organic fertilizer product, without any subsequenttreatment steps. In other aspects, an aerated, stabilized slurry can besubjected to one or more subsequent treatment steps, such as, forexample, a filtration step to remove suspended solids. In yet otheraspects, such a slurry can be subjected to one or more steps, asdescribed herein.

Separation

In one aspect, any suspended solids present in the slurry stream, afterpH and temperature adjustment, can be removed, for example, viafiltration or any other mechanical means. In various aspects, one ormore of mechanical screening, microfiltration, electro coagulation,clarification, or a combination thereof, can be used to remove suspendedsolids from the slurry. In another aspect, a settling tank can be usedto allow particles, sediments, and solids to gradually sink due togravity. In another aspect, a centrifuge, such as, for example, adecanter centrifuge can be used to provide a continuous separation ofliquids and solids.

When subjected to the forces of a decanter centrifuge, denser solidparticles are pressed outwards against a rotating bowl wall, while aless dense liquid phase forms a concentric inner layer. Dam plates canbe used to vary the depth of the liquid (i.e., the pond) as required. Insuch an aspect, sediment formed by the solid particles is continuouslyremoved by a screw conveyor, which rotates at a different speed than thebowl. As a result, solids are gradually “ploughed” out of the pond andup a conical “beach”. The centrifugal force compacts the solids andexpels the surplus liquid. The dried solids then be discharged from thebowl, and the clarified liquid phase can overflow the dam platessituated at the opposite end of the bowl. Baffles within the centrifugecasing can direct the separated phases into flow paths and preventcross-contamination. The speed of the screw conveyor can also beautomatically adjusted by use of the variable frequency drive (VFD) inorder to adjust to compensate for variations in the solids load.

In another aspect, separation of solids and liquids, for example, via adecanter centrifuge, can be performed in a manner so as to selectivelyremove one or more nutrients from either the solid or the liquid phase.In one aspect, a decanter centrifuge can continuously separate solidsand liquids and can remove all or a portion of phosphorus and/orphosphorus containing compounds from, for example, the liquid portion ofthe material. In one aspect, a liquid, such as, for example, athixotropic liquid from a bioreactor can be centrifuged at a temperatureof from about 50° C. to about 95° C., for example, about 50, 55, 60, 65,70, 75, 80, 85, 90, or 95° C.; from about 60° C. to about 95° C.; fromabout 60° C. to about 80° C.; from about 60° C. to about 70° C.; or fromabout 60° C. to about 65° C. In one aspect, centrifuging an animal wastematerial at temperatures of from about 65° C. to about 95° C. can resultin more efficient separation, wherein the solids (e.g., cake) portionhas a lower moisture content and the liquid centrate portion exhibitsimproved quality and requires less filtration or polishing downstream.In another aspect, material, such as, for example, a thixotropic liquidor a slurry comprising solid and liquid animal waste, can be fed to adecanter centrifuge at a rate of from about 5 gallons per minute toabout 25 gallons per minute, for example, about 5, 6, 7, 8, 9, 10, 11,12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, or 25 gallons perminute. In other aspects, the temperature and/or feed rate of acentrifuge can vary, and the present invention is not intended to belimited to any particular temperature or feed rate conditions. In oneaspect, a centrifuge, such as, for example, a decanter centrifuge, canselectively remove one or more chemicals or nutrients from an animalwaste material. In another aspect, a decanter centrifuge, operated, forexample, at the temperatures and feed rates described above, canselectively remove phosphorus from an animal waste sample. In variousaspects, a decanter centrifuge can selectively remove from about 25 wt.% to about 90 wt. % of phosphorus present in an animal waste material;from 30 wt. % to about 80 wt. % of phosphorus, from about 40 wt. % toabout 70 wt. % of phosphorus, or about 50 wt. % of phosphorus. In yetanother aspect, a decanter centrifuge can selective remove at leastabout 30 wt. %, at least about 40 wt. %, at least about 50 wt. %, atleast about 60 wt. %, at least about 70 wt. %, or at least about 80 wt.% of phosphorus from an animal waste material. In still other aspects,the addition of one or more additives, such as, for example,flocculants, polymers, or the like, can facilitate even higher levels ofphosphorus removal. Thus, in one aspect, the methods described hereincan provide an organic fertilizer product have a controlled orpredetermined phosphorus level. Such fertilizer products can be usefulin preventing the oversaturation of phosphorus materials in certainsoils. In still other aspects, the use of a centrifuge, such as, forexample, a decanter centrifuge, to selectively remove one or morechemical compounds or nutrients, such as, for example, phosphorus, asdescribed above, can be performed as a standalone procedure, without theneed to treat with acid, heat, aerate, filter, sterilize, or subject toan autothermal thermophilic aerobic bioreaction.

In one aspect, the solids stream emanating from a decanter centrifugecan be processed in a granulator system. Such a granulator system cancomprises a rotary drum agglomerator. An overall system can comprise areactor where dewatered solids from a decanter centrifuge are blendedwith fertilizer enhancing chemicals as well as agglomeration enhancers.In one aspect, agglomeration enhancers can comprise molasses derivedfrom sugarcane or sugar beet processing. In another aspect,agglomeration enhancers can comprise lignins, for example, derived as abyproduct from papermills. In other aspects, an agglomeration enhancer,if used, can comprise any other suitable material for agglomeratingsolids for use as a fertilizer product. In one aspect, the enhancedsolids can be further blended in a paddle mixer to optimize homogeneity.This product can then be directed into a rotary drum agglomerator for afinal granulation and dehydration step.

In various aspects, a rotary drum agglomerator can be internally heatedusing, for example, a fuel-air combustion system. The hot gases aredirected inside the rotary drum and the temperatures and residence timesare maintained such that the final product is free of microorganisms andpathogens. Consequently, the final product can be defined as a sterilefertilizer solid. In order to maintain sterility, a sufficient amount ofresidence time is maintained in the presence of hot air so that themoisture content of the sterile product is maintained below about 12%.The resulting stream can then be directed to an appropriate packagingprotocol that can range from loading the sterile fertilizer solids intotrucks, super sacks or bags, as appropriate for current marketconditions.

Autothermal Thermophilic Aerobic Bioreaction

In various aspects, the separated liquid phase, for example, from adecanter centrifuge, can be subjected to a first stage of an aerobicbioreactor. In one aspect, such a bioreactor can provide an autothermalthermophilic aerobic bioreaction (ATAB), an exothermic process where astream, such as, for example, a liquid stream from a decantercentrifuge, is subjected to temperatures greater than about 55° C. andhydraulic retention times of from about 2 to about 18 days. In oneaspect, an autothermal thermophilic aerobic bioreactor can provide aself-sustaining bioreaction that can maintain waste materialtemperatures from about 30° C. to about 70° C., or from about 60° C. toabout 70° C.

In various aspects, organic solids can be degraded, and the heatreleased during microbial degradation can maintain thermophilictemperatures within the mixture. In another aspect, autothermalthermophilic aerobic bioreaction can produce a biologically stableproduct while reducing both sludge mass and volume. It is important tonote that aerobic microbial degradation of organic matter, such asanimal waste, will not produce chemical compounds known to bedetrimental to plant growth. In contrast, anaerobic microbialdegradation processes are known to produce noxious and/or phytotoxiccompounds, unsuitable for use in fertilizer products.

In another aspect, thermophilic digestion can occur over a temperaturerange of from about 45° C. to about 70° C. In some cases, for reactorsreceiving high biodegradable loading, hyper thermophilic conditions withtemperatures exceeding 70° C. can be present, and the present inventionis not intended to be limiting to any particular thermophilictemperature conditions; however, hyper thermophilic conditions aretypically unsuitable for optimal solids digestion. On the other hand, atlower temperatures ranging from about 10° C. to about 35° C., mesophilicconditions predominate. These mesophilic conditions can result in adistinctly different type of digestion reaction methodology. Given theoptimal thermophilic digestion range, thermofiles whose physiologicalnature and lifestyle is probably a bacterial grouping comparable to thatwhich would be found within composting biomass. Conventional compositingtechniques can take multiple months to complete and the resulting endproducts are not easy to handle liquids. In addition, conventionalcomposting techniques also require large amounts of space and frequentturning to insure sufficient aeration and temperature uniformity.Conventional composting techniques require months to cure the compostingmaterial and get rid of substances that can retard plant growth.Conventional composting techniques can also leave significant quantitiesof pathogens present in the compost material. In still other aspects,conventional composting techniques using materials having a carbon tonitrogen ratio below about 20:1, such as, for example, chicken manure,typically release significant quantities of nitrogen. Thus, conventionalcomposting techniques cannot retain beneficial nitrogen nutrients in,for example, chicken manure, without the addition of other substances.In contrast, the methods of the present invention retain all orsubstantially all of the nitrogen nutrient present in the chicken manureand can release these nitrogen nutrients quickly upon use as afertilizer.

Thus, in one aspect, it can be desirable to maintain thermophilicconditions for an extended period of time. The use of varioustemperature controlling means, such as, for example, steam, immersionheaters, jacket heaters, refrigerant coils, ice baths, can be utilizedto ensure that thermophilic conditions are maintained.

In one aspect, a challenge in maintaining aerobic thermophilicconditions is to keep the process sufficiently aerobic by meeting orexceeding the oxygen demand while operating at the elevated temperatureconditions of between about 45° C. and about 70° C. One reason for thisdifficulty is that as the process temperature increases, the saturationvalue of the residual dissolved oxygen decreases. Another challenge isthat the activity of the thermophilic micro-organisms increases withinincreasing temperatures resulting in increased oxygen consumption by themicro-organisms. Because of the above conundrum, greater amounts ofoxygen must be imparted into the biomass containing solutions tomaintain ideal reaction (e.g., decomposition) conditions. Thus, in oneaspect, aerobic thermophilic conditions are maintained via continuousadjustment of air or oxygen levels and continuous adjustment oftemperature conditions.

In one aspect, oxygen can be imparted using a jet aeration device. Jetaerators utilize two-phase jet nozzles to supply atmospheric oxygen tochemical and biological treatment processes. Special process benefitscan include high oxygen transfer efficiency, independent control ofoxygen transfer and mixing, superior mixing, capital and energy savings,and reduced off-gas. These combine large volumes of recirculated liquidwith low pressure air in a proprietary mixing nozzle. Recirculatedliquid can be pumped through the inner, primary nozzle, creating a highvelocity liquid stream, while air is fed into the secondary, outernozzle. The high velocity liquid stream shears the air into a turbulent,fine dispersion of gas and liquid. This device comprises of an airheader having a multiplicity of openings/jets through which a gastransported through the air header exits. Simultaneously, a liquidheader running parallel to the air header and having the samemultiplicity of openings through which the biosolids containing solutionis pumped and exits through the openings.

In one aspect, an oxygen-rich gas/liquid plume can be then dischargedout of the secondary nozzle, entraining the surrounding liquid. Thegas/liquid plume has both horizontal and vertical energy components andprovides intense mixing of the basin.

In addition to the vertical component caused by bubble rise, therecirculated liquid can impart a horizontal component of mixing energy.Full mixing of the basin can thus be achieved without the need for fullfloor coverage.

In addition to the efficiency inherent with a fine bubble dispersion ofa gas into a liquid, the turbulent nature of jet aeration producesconstant renewal of the gas/liquid interface, further facilitatingoxygen transfer. The alpha factor is a relative measure of oxygentransfer performance in process wastewater vs. clean water. Thisconstant surface renewal of the gas/liquid interface results in alphafactors that are higher when compared to most other fine bubble diffusertechnologies.

In one aspect, a well configured operating system should maintainambient dissolved oxygen levels of approx. 4 mg/l and 6 mg/l, forexample, about 4, 4.2, 4.4, 4.6, 4.8, 5, 5.2, 5.4, 5.6, 5.8, or 6 mg/l.In other aspects, the bioreaction should maintain a dissolved oxygenlevel of at least about 1.5 mg/1, at least about 2 mg/1, at least about3 mg/1, or at least about 4 mg/l. It should be noted that the saturationlevel of oxygen in an aqueous solution between about 45° C. and about70° C. is from about 4 mg/l to about 6 mg/l. In another aspect, thedissolved oxygen level should be maintained at a level of at least about30% of the saturation level, at least about 50% of the saturation level,or at least about 75% of the saturation level. Highly activethermophiles maintain a vigorous oxygen uptake that is normally observedin mesophilic digestion units and consequently, the operating dissolvedoxygen level should be kept low in order to maintain an appropriate masstransfer gradient. Operationally, one can readily picture situationswhere active thermophiles create a low dissolved oxygen environmentwhere that type of measurement becomes irrelevant. Aerobic conditions atthis stage of the treatment process can help strip the waste material ofany undesirable compounds which can be present. In one aspect, suchundesirable compounds, such as, for example, H2S and/or mercaptans, canbe present from previous anaerobic activity prior to treatment of theanimal waste, for example, storage of waste prior to treatment.

In one aspect, the aerated slurry stream can be sent directly to thefirst stage of an aerobic bioreactor. If needed, the contents can beheated by direct steam injection to an optimum temperature of betweenabout 50° C. and about 75° C. It should also be noted that the injectionof air to maintain a desirable dissolved oxygen level can also adjustthe temperature by, for example, evaporative or direct cooling. Thecontents of the bioreactor can then be mixed using a recirculation pump.Air can be injected into the tank to maintain an aerobic environment.Water can also be added to maintain a moisture concentration of betweenabout 80 wt. % and about 98 wt. % water. Residence time in thebioreactor can depend upon solids loading, temperature, air flow andaddition of any additives to create specific formulations. In someaspects, other biomass materials, such as, for example, hydrolyzedfeather meal, can be added to the bioreactor. Such an addition canchange the residence time necessary in the bioreactor. In one aspect,residence time in the first stage of the bioreactor can be between about1 day and about 18 days, for example, about 1, 2, 3, 4, 5, 6, 7, 8, 9,10, 11, 12, 13, 14, 15, 16, 17, or 18 days; or preferably less thanabout 5 days, for example, about 1, 2, 3, 4, or 5 days. After a setamount of time in the first stage, a predetermined amount of materialcan be sent to the second stage of a bioreactor for final stabilization.

In another embodiment the aerated slurry is first centrifuged, and theresultant colloidal suspension can be sent to the first stage aerobicbioreactor. If needed, the contents can be heated by, for example,direct steam injection to a temperature of from about 50° C. and about75° C. The contents of the bioreactor can optionally be mixed, forexample, in a continuous manner, using a recirculation pump. Air canalso be injected into the tank to maintain an aerobic environment. Itshould be noted that in one aspect, an aerobic environment should bemaintained at all times during the process. Water can also be added tomaintain the proper moisture concentration of between about 80 wt. % andabout 98 wt. % water. Residence time in the bioreactor can depend uponsolids loading, temperature, air flow and addition of any additives tocreate specific formulations. In some aspects, other biomass materials,such as, for example, hydrolyzed feather meal, can be added to thebioreactor. Such an addition can change the residence time necessary inthe bioreactor. In one aspect, residence time in the first stagebioreactor is between about 1 day and about 18 days, preferably lessthan about 5 days. After a set amount of time in the first stage, apredetermined amount of material can be sent to the second stagebioreactor for final stabilization.

In other aspects, the second stage of an autothermal thermophilicaerobic bioreactor can further aerate a waste material. In one aspect,the conditions of a second stage bioreactor can be the same as orsubstantially similar to the first stage bioreactor. In other aspects,the conditions (e.g., temperature, dissolved oxygen level, etc.) canvary from those of the first stage bioreactor. In one aspect, the secondstage of a bioreaction can facilitate further degradation of volatilesolids or the addition of substances that can produce a product havinggreater nutrient values. In another aspect, a second stage can be usefulto ensure prolonged contact time at the desirable temperature and oxygenlevels for any given portion of the material being treated. In anotheraspect, given the continuous nature of the bioreaction system, a secondstage can prevent the inadvertent passage of untreated or undigestedwaste material through the bioreaction system.

Sterilization

All or any portion of the liquid and/or solid product stream canoptionally be subjected to a sterilization step to remove and/or killall or a portion of pathogens that can be present in the animal manure.It should understand that the specific pathogens that can be present canvary depending upon the animal and originating facility, along with thehandling history of the animal waste. A sterilization step, ifperformed, can utilize any suitable means for removing and/or killingpathogens.

In one aspect, the contents of the second stage bioreactor can be pumpedcontinuously, for example, using a high pressure pump that is capable ofgenerating discharge pressures of up to 75 psig, into a sterilizer, suchas, for example, a continuous sterilizer. In one aspect, sterilizationcan be achieved by applying heat and optionally pressure.

The degree of sterilization is commonly expressed by multiples of thedecimal reduction time D denoting the time needed to reduce the initialnumber NO to one tenth (10⁻¹) of its original value. Then the number ofmicroorganisms N after sterilization time t is given byN/N0=10^((−t/D)). D is a function of sterilization conditions and varieswith the type of microorganism, temperature, water activity, pH etc. Forsteam sterilization, temperature (in ° C.) is typically given as index.For sterilization, a reduction by one million (10⁻⁶) is minimallyrequired with six times D. Theoretically, the likelihood of survival ofan individual microorganism is never zero.

A widely used method for heat sterilization is a plug flow tubular unitsometimes called a hairpin sterilizer. Such sterilizers commonly usesteam heated to from about 121° C. to about 134° C. (i.e., about 250° F.to about 273° F.). To achieve sterility, a holding time of at least 15minutes at about 121° C. (i.e., about 250° F.) at 100 kPa (i.e., 15psi), or 3 minutes at 134° C. (i.e., 273° F.) at 100 kPa (15 psi) can beused.

According to this method, the product is indirectly heated to atemperature of from about 90° C. to about 100° C. and directly heatedusing steam injection up to temperatures preferably ranging from about120° C. to about 135° C. Direct contact heat transfer is conducted byinjecting precisely metered amounts of steam into the process fluid.Injecting this steam directly results in a rapid heat transfer and veryefficient energy usage. It should be noted that this direct steaminjection method eliminates what is commonly referred to as the “heattransfer barrier”. This steam heating protocol can be 100% thermallyefficient because both the sensible and the latent heat of steam areutilized.

In one aspect, steam injection in this application can be conducted byexternal modulation using an appropriately sized control valve thatthrottles steam as needed. This control valve can readily vary thevelocity of steam injection into the process liquid as well as thepressure relationship between steam and the process liquid. In anotheraspect, steam leaving the control valve can be directed into the processfluid using a sparging nozzle with multiple perforations to optimizesteam dispersion.

In various aspects, the present invention relates to a method forcontinuous sterilization and an arrangement for carrying through thismethod. The product can be preheated by indirect heating and then heatedto sterilization temperatures of between about 115° C. to about 150° C.by means of steam injected directly into the flow of the product bymeans of a throttling valve. In one aspect, the sterilizer can beinsulated, whereas in another aspect, it can be jacketed. In anotheraspect, the product can be cooled after sterilization by, for example,isenthalpic depressurization. In such an aspect, the depressurizedsterilized liquid product stream results in an environment where thewater vapor emanates out of the depressurized product. In anotheraspect, heat removed from the liquid product stream during a coolingstep, for example, using a heat exchanger, can be used to heat anotherportion of the manure or product stream, for example, an incoming liquidstream to a sterilizer.

In other aspects, a sterilization step, if performed, can compriseexposing a product stream to ultraviolet radiation for a period of timesufficient to kill all or a portion of the pathogens present therein. Inanother aspect, a sterilization step, if performed can comprisecontacting the product stream with a chemical agent, such as, forexample, chlorine dioxide, for a period of time sufficient to kill allor a portion of pathogens present therein. In other aspects, asterilization step, if performed, can comprise other techniques or acombination of two or more techniques recited herein or known in the artto kill pathogens. A chemical agent, if utilized, can comprise any agentsuitable for reducing or killing pathogens. In one aspect, a chlorinebased agent can be used. In another aspect, a solution comprisingchlorine dioxide can be used. In yet another aspect, a material, such assodium hypochlorite, can be used. A chemical agent, if used, cancomprise a solid and/or a liquid and can have any concentration suitablefor killing pathogens in an animal waste product. In still otheraspects, no chemical or chlorine based chemical agents are used tosterilize all or a portion of a product stream.

Offgas Treatment

In one aspect, the depleted air stream leaving the primary aeration tankcan be directed to a biofilter. In another aspect, the depleted airstream exiting the first stage ATAB and the depleted air stream leavingthe second stage ATAB can be combined. In one aspect, both streams cancontain significant amounts of ammonia and water vapor. In such anaspect, the combined streams can be directed through a condenser thatcan optionally be water cooled. The condensate emanating from thiscondenser can then be directed to an ammonia water receiver. In anotheraspect, due to the significant amount of saturated water vapor,virtually all the ammonia can be solubilized in the condensate. Theammoniacal water can be continuously pumped out and directed into a baseproduct receiver or formulated product receiver depending upon thespecific formulations desired.

In another aspect, the depleted air and the air from stream are bothcombined and directed to a biofilter.

In one aspect, the biofilter is a device that uses microbes to consumepollutants from a contaminated air stream. In one aspect, the biofilteris a rectangular box that contains an enclosed plenum at the bottom witha support rack above the plenum. On top of the support rack is a bed ofmedia where the media is comprised of peat, bark, etc. In one aspect,the support rack can be perforated to enable the air from the plenum tomove into the bed media to contact the microbes therein. The bed can bemaintained at a temperature ranging from about 60° F. to about 100° F.,or in the range of from about 80° F. to about 90° F. It should be notedthat air streams directed to the biofilter can be saturated with water,as microbes need moisture to survive and moisture creates a biofilm thatabsorbs pollutants from the air stream to be assimilated by microbes.Pollutants are the main source of food and energy for the microbes, butthey can additionally require micronutrients for sustenance. Thesemicronutrients can typically be provided via the decay of organic bedmedia.

In one aspect, a biofilter, if utilized, can perform best when the pHranges from about 6 to about 8, for example, about 6, 7, or 8. Whencompounds such as hydrogen sulfide, organic sulfurs, halogens, etc.decompose, they result in the production of acids that could lower pHand eventually destroy microbes. In one embodiment, this is mitigated bythe addition of oyster shells into the bed media wherein the shells willslowly decompose along with the organic bed media. The bed media in thebiofilter can eventually or periodically be replaced. A biofilter, ifpresent, can comprise one or more substrates, each containing the sameor different bacteria populations, that can scrub air as it passesthrough the biofilter, removing contaminants before the air is vented toatmosphere. In another aspect, each substrate and bacteria can beselected to target one or more specific chemical compounds.

Product Receiving Section

In one aspect, the product stream from an ammonia water receiver can bedirected to a base product receiver. Such a base product receiver can beequipped with an agitator that can maintain the colloidal components ofthe liquid stream in the homogeneous suspension. Periodically, thecontents of the base product receiver can be pumped out into appropriatetanks for shipment to the marketplace.

In another embodiment, product stream can be directed to a formulatedproduct receiver. In one aspect, one or more additional nutrients can beadded to a product stream. In another aspect, one or more organicnutrients can be added to a product stream. In one aspect, sodiumnitrate or an organic sodium nitrate, such as, for example, Chileansodium nitrate, can be introduced into the product line leading to theformulated product receiver or the formulated product receiver itself.In another aspect, the quantity of the sodium nitrate, if used, can bepredetermined to ensure that the nitrogen content of the formulatedproduct is appropriate to the category of fertilizer product being made.Another aspect of the invention enables the introduction of Single SuperPhosphate (SSP) into the product line leading to the formulated productreceiver or the formulated product receiver itself. The quantity of SSP,if used, can be predetermined to ensure that the phosphorus component ofthe formulated product is appropriate to the category of fertilizerproduct being made. In another aspect, an organic sodium nitrate, singlesuper phosphate, or other additive nutrients can be introduced into theformulated product receiver by, for example, gravimetric solid feederprotocol or in a concentrate form, whichever is appropriate for theapplication.

In yet another aspect, the formulated product receiver can be equippedwith an agitator to ensure that the formulation maintains theappropriate homogeneity. In one aspect, the contents of the base productreceiver can be periodically be conveyed to appropriate vessels orstorage areas for ultimate shipment to the marketplace.

Organic Fertilizer Products

In various aspects, a liquid organic fertilizer product prepared by themethods of the present disclosure can contain suspended solids. In oneaspect, all or a portion of suspended solids in the liquid organicfertilizer product can be separated by, for example, pumping the liquidthrough a 200 mesh screen. The separated solids can optionally beconveyed to an aerobic reactor for subsequent treatment, as describedabove.

In one aspect, a liquid or solid organic fertilizer product prepared bythe methods described herein can meet all current USDA requirements foran organic fertilizer. In another aspect, an organic fertilizer productproduced by the methods described herein can contain no or substantiallyno phytotoxins or other plant growth retarding substances. In anotheraspect, a liquid or solid organic fertilizer product prepared by themethods described herein can comprise no or substantially no pathogens.In one aspect, a liquid or solid organic fertilizer product can have nodetectable pathogens as measured by conventional means used in organicfertilizer products.

In an exemplary aspect, an organic liquid fertilizer product prepared bythe methods of the present invention can exhibit a composition asillustrated in Table 2, below.

TABLE 2 Composition of Exemplary Liquid Organic Fertilizer ProductNUTRIENTS Analysis Nitrogen % 1-3 Phosphorus % <0.5 Potassium % 1-3Sulfur % >0.2 Calcium % 1-2 Magnesium % 1-2 Micronutrients Zinc ppm >100Iron ppm >300 Manganese ppm >100 Copper ppm <20 Boron ppm <20

In other aspects, a liquid organic fertilizer product can comprise acolloidal suspension. In one aspect, a liquid organic fertilizer productcan be capable of being sprayed through a nozzle, for example, a 200mesh nozzle. In other aspects, a liquid organic fertilizer product canhave a brown color. In another aspect, a liquid or solid organicfertilizer product can be odorless or can have a slight pungent odor. Instill another aspect, a liquid or solid organic fertilizer product doesnot exhibit an odor typically associate with animal feces.

In another aspect, a liquid organic fertilizer product can have pH offrom about 4 to about 7, for example, about 4, 4.5, 5, 5.5, 6, 6.5, or7; or from about 5 to about 6, for example, about 5, 5.1, 5.2, 5.3, 5.4,5.5, 5.6, 5.7, 5.8, 5.9, or 6. In still another aspect, a liquid organicfertilizer product can be non-corrosive. In still another aspect, aliquid organic fertilizer product can be compatible with conventionalagricultural spray equipment.

In other aspects, a solid organic fertilizer prepared by the methods ofthe present disclosure can comprise each of the primary, secondary, andmicro-nutrients described herein, and can have a moisture content ofless than about 20 wt. %, or less than about 12 wt. %. In anotheraspect, such a solid organic fertilizer product can be in a granulatedor pelletized form for distribution and eventual use as a fertilizer.

It should be understood that the methods and devices described hereinare intended to be exemplary, and the present invention is not intendedto be limited to any particular steps or components. Accordingly, anyindividual steps, devices, or combinations thereof can be present or notpresent in various aspects of the invention. For example, the methodsand devices of the present disclosure can lack one or more components,but are still intended to be covered by this disclosure.

It will be apparent to those skilled in the art that variousmodifications and variations can be made in the present inventionwithout departing from the scope or spirit of the invention. Otherembodiments of the invention will be apparent to those skilled in theart from consideration of the specification and practice of theinvention disclosed herein. It is intended that the specification beconsidered as exemplary only, with a true scope and spirit of theinvention being indicated by the following claims.

The present invention can be described in one or more of the followaspects or combinations thereof.

Aspect 1: A process for manufacturing an organic fertilizer product, theprocess comprising: providing an animal waste composition comprising ananimal waste, contacting the animal waste composition with an acid toproduce a stabilized animal waste composition, aerating the animal wastecomposition, and separating a solid component and a liquid component ofthe stabilized animal waste composition.

Aspect 2: The process of aspect 1, wherein the animal waste compositioncomprises chicken manure.

Aspect 3: The process of aspect 1, wherein the animal waste compositioncomprises poultry litter, broiler litter, layered manure, or acombination thereof.

Aspect 4: The process of aspect 1, wherein the animal waste compositioncomprises a manure slurry.

Aspect 5: The process of aspect 1, wherein the animal waste compositionhas a moisture content of from about 20 wt. % to about 95 wt. %.

Aspect 6: The process of aspect 1, wherein the animal waste compositionhas a moisture content of at least about 80 wt. %.

Aspect 7: The process of aspect 1, wherein contacting further comprisesadjusting the moisture content of the animal waste composition to alevel of at least about 75 wt. %.

Aspect 8: The process of aspect 1, wherein contacting further comprisesadjusting the moisture content of the animal waste composition to alevel of at least about 80 wt. %.

Aspect 9: The process of aspect 1, wherein contacting further comprisesadjusting the moisture content of the animal waste composition to alevel from about 80 wt. % to about 98 wt. %.

Aspect 10: The process of aspect 1, wherein contacting further comprisesadjusting the moisture content of the animal waste composition via theaddition of water, a nutrient enriched liquid, or a combination thereof.

Aspect 11: The process of aspect 1, wherein the acid comprises citricacid.

Aspect 12: The process of aspect 1, wherein the acid comprises anaqueous solution of citric acid.

Aspect 13: The process of aspect 1, wherein the acid comprises a 50 wt.% aqueous solution of citric acid.

Aspect 14: The process of aspect 1, wherein contacting comprising anaddition of acid sufficient to adjust the pH of the animal wastecomposition to a value of from about 4 to about 7.

Aspect 15: The process of aspect 1, wherein contacting comprising anaddition of acid sufficient to adjust the pH of the animal wastecomposition to a value of from about 5 to about 7.

Aspect 16: The process of aspect 1, wherein contacting comprising anaddition of acid sufficient to adjust the pH of the animal wastecomposition to a value of from about 6 to about 7.

Aspect 17: The process of aspect 1, wherein contacting further comprisesheating the animal waste composition to promote the growth of mesophilicbacteria.

Aspect 18: The process of aspect 1, wherein contacting further comprisesheating the animal waste composition to a temperature of from about 30°C. to about 70° C.

Aspect 19: The process of aspect 1, wherein contacting further comprisesheating the animal waste composition to a temperature of from about 30°C. to about 35° C.

Aspect 20: The process of aspect 1, wherein contacting further comprisesheating the animal waste composition to a temperature of from about 50°C. to about 70° C.

Aspect 21: The process of aspect 1, wherein contacting further comprisesheating the animal waste composition to a temperature of from about 60°C. to about 70° C.

Aspect 22: The process of aspect 1, wherein contacting further comprisesheating the animal waste composition via injection of steam.

Aspect 23: The process of aspect 1, wherein after contacting and priorto aerating, the stabilized animal waste composition is transferred toan aeration vessel.

Aspect 24: The process of aspect 1, wherein after contacting and priorto aerating, the stabilized animal waste composition is filtered toremove stones, feathers, wood chips, or a combination thereof.

Aspect 25: The process of aspect 1, wherein aerating the stabilizedanimal waste composition comprises sparging with air or oxygen.

Aspect 26: The process of aspect 1, wherein a pH of the stabilizedanimal waste composition is maintained at a level of from about 3 toabout 7 during aerating.

Aspect 27: The process of aspect 1, wherein a pH of the stabilizedanimal waste composition is maintained at a level of from about 4 toabout 7 during aerating.

Aspect 28: The process of aspect 1, wherein a pH of the stabilizedanimal waste composition is maintained at a level of from about 5 toabout 7 during aerating.

Aspect 29: The process of aspect 1, wherein a pH of the stabilizedanimal waste composition is maintained at a level of from about 6 toabout 7 during aerating.

Aspect 30: The process of aspect 1, wherein an aerobic environment ismaintained at all times during contacting and aerating.

Aspect 31: The process of aspect 1, wherein aerating comprises heatingthe stabilized animal waste composition to a temperature of from about50° C. to about 80° C.

Aspect 32: The process of aspect 1, wherein aerating comprises heatingthe stabilized animal waste composition to a temperature of from about60° C. to about 70° C.

Aspect 33: The process of aspect 1, wherein aerobic conditions aremaintained throughout the process.

Aspect 34: The process of aspect 1, wherein conditions are maintainedthroughout the process sufficient to prevent the growth of anaerobicbacteria.

Aspect 35: The process of aspect 1, further comprising sterilizing thestabilized animal waste composition.

Aspect 36: The process of aspect 35, wherein sterilizing comprisingheating the stabilized animal waste composition to a temperaturesufficient to kill all or substantially all pathogens.

Aspect 37: The process of aspect 1, wherein separating comprisescentrifuging the stabilized animal waste composition to separate solidand liquid components thereof.

Aspect 38: The process of aspect 1, wherein separating comprises acontinuous separation of solid and liquid components.

Aspect 39: The process of aspect 1, wherein a temperature of from about65° C. to about 95° C. is maintained during separating.

Aspect 40: The process of aspect 1, wherein separating comprisesseparating the solid component and liquid component of the stabilizedanimal waste composition using a decanter centrifuge.

Aspect 41: The process of aspect 1, wherein separating comprisesselectively concentrating one or more nutrients in the solid component,the liquid component, or a fraction thereof.

Aspect 42: The process of aspect 1, wherein separating comprisesselectively removing all or a portion of one or more nutrients from thesolid component, the liquid component, or a combination thereof.

Aspect 43: The process of aspect 1, wherein at least about 30 wt. % ofphosphorus present in the stabilized animal waste composition isselectively removed.

Aspect 44: The process of aspect 1, wherein the separated solidcomponent is granulated.

Aspect 45: The process of aspect 1, wherein the separated solidcomponent is contacted with an agglomeration enhancer.

Aspect 46: The process of aspect 1, wherein the separated solidcomponent is dried to a moisture level of less than about 12 wt. %.

Aspect 47: The process of aspect 1, wherein the separated solidcomponent is heated to a temperature sufficient to kill all orsubstantially all pathogens.

Aspect 48: The process of aspect 1, wherein separated solid componentcomprises a solid organic fertilizer product.

Aspect 49: The process of aspect 1, further comprising subjecting theseparated liquid component and/or the solid component to an autothermalthermophilic aerobic bioreaction.

Aspect 50: The process of aspect 1, further comprising subjecting theseparated liquid component and/or the solid component to a two stageautothermal thermophilic aerobic bioreaction.

Aspect 51: The process of aspect 49, wherein the autothermalthermophilic aerobic bioreaction comprises heating the stabilizedseparated liquid component to a temperature of at least about 45° C.

Aspect 52: The process of aspect 49, wherein the autothermalthermophilic aerobic bioreaction comprises heating the stabilizedseparated liquid component to a temperature of at least about 55° C.

Aspect 53: The process of aspect 49, wherein the autothermalthermophilic aerobic bioreaction comprises heating the stabilizedseparated liquid component to a temperature of from about 50° C. toabout 80° C.

Aspect 54: The process of aspect 49, wherein the autothermalthermophilic aerobic bioreaction comprises heating the stabilizedseparated liquid component to a temperature of from about 50° C. toabout 75° C.

Aspect 55: The process of aspect 49, wherein the autothermalthermophilic aerobic bioreaction comprises maintaining aerobic conditionand a temperature suitable for the promotion of thermophilic bacteriafor a period of time.

Aspect 56: The process of aspect 49, wherein the autothermalthermophilic aerobic bioreaction comprises maintaining a dissolvedoxygen level in the separated liquid component of from about 4 mg/l toabout 6 mg/l.

Aspect 57: The process of aspect 49, wherein the autothermalthermophilic aerobic bioreaction comprises maintaining a dissolvedoxygen level in the separated liquid component of at least about 1.5mg/l.

Aspect 58: The process of aspect 55, wherein the period of timecomprises from about 1 day to about 18 days.

Aspect 59: The process of aspect 55, wherein the period of timecomprises up to about 5 days.

Aspect 60: The process of aspect 49, wherein the autothermalthermophilic aerobic bioreaction comprises injection of air and/oroxygen using a jet aeration device to maintain aerobic conditions.

Aspect 61: The process of aspect 50, wherein each of a first stage and asecond stage of the autothermal thermophilic aerobic bioreactioncomprises maintaining aerobic conditions and a temperature sufficient topromote thermophilic bacterial for a period of time.

Aspect 62: The process of aspect 61, wherein the dissolved oxygen leveland temperature of the separated liquid component are the same orsubstantially the same in each of the first stage and the second stage.

Aspect 63: The process of aspect 61, wherein the dissolved oxygen leveland temperature of the separated liquid component in the second stageare different from the same in the first stage.

Aspect 64: The process of aspect 49, wherein the separated liquidcomponent, after the first stage or the second stage of the autothermalthermophilic aerobic bioreaction, is subjected to sterilization to killall or substantially all pathogens present therein.

Aspect 65: The process of aspect 49, wherein the separated liquidcomponent, after the second stage of the autothermal thermophilicaerobic bioreaction, is subjected to sterilization to kill all orsubstantially all pathogens present therein.

Aspect 66: The process of aspect 64, wherein sterilization comprisesheating the separated liquid component to a temperature of from about120° C. to about 135° C.

Aspect 67: The process of aspect 64, wherein after sterilization, nodetectable pathogens exist in the separated liquid component.

Aspect 68: The process of aspect 49, wherein an offgass from the firststage, the second stage, or a combination thereof from the autothermalthermophilic aerobic bioreaction can be treated with an ammonia-waterreceiver.

Aspect 69: The process of aspect 49, wherein an offgass from the firststage, the second stage, or a combination thereof from the autothermalthermophilic aerobic bioreaction can be treated a biofilter.

Aspect 70: The process of aspect 49, wherein the separated liquidcomponent, after the autothermal thermophilic aerobic bioreaction,comprises an organic liquid fertilizer product.

Aspect 71: The process of aspect 70, wherein one or more additionalnutrients can be contacted with the organic liquid fertilizer product.

Aspect 72: The process of aspect 71, wherein the one or more additionalnutrients comprise organic nutrients.

Aspect 73: The process of aspect 71, wherein the one or more additionalnutrients comprises organic sodium nitrate, single super phosphate, or acombination thereof.

Aspect 74: The process of aspect 70, wherein one or more biomassmaterials can be contacted with the organic liquid fertilizer product.

Aspect 75: The process of aspect 74, wherein the one or more biomassmaterials can comprise hydrolyzed feather meal.

Aspect 76: A solid organic fertilizer product resulting from the processof any of aspects 1-48.

Aspect 77: The solid organic fertilizer product of aspect 76, meetingUnited States Department of Agriculture requirements for an organicfertilizer.

Aspect 78: The solid organic fertilizer product of aspect 76, being freefrom or substantially free from pathogens.

Aspect 79: A liquid organic fertilizer product resulting from theprocess of any of aspects 1-75.

Aspect 80: The liquid organic fertilizer product of aspect 79, beingfree from or substantially free from pathogens.

Aspect 81: The liquid organic fertilizer product of aspect 79, meetingUnited States Department of Agriculture requirements for an organicfertilizer.

Aspect 82: The liquid organic fertilizer product of aspect 79, capableof flowing through a 200 mesh screen.

Aspect 83: The liquid organic fertilizer product of aspect 79, capableof being sprayed through a nozzle.

Aspect 84: The liquid organic fertilizer product of aspect 79, capableof being sprayed using conventional liquid agricultural equipment.

Aspect 85: The liquid organic fertilizer product of aspect 79, having abrown color.

Aspect 86: The liquid organic fertilizer product of aspect 79, having nounpleasant odor.

Aspect 87: The liquid organic fertilizer product of aspect 79, having noodor typically associated with animal feces.

Aspect 88: The liquid organic fertilizer product of aspect 79, having apH from about 4 to about 7.

Aspect 89: The liquid organic fertilizer product of aspect 79, having anitrogen concentration of from about 1 wt. % to about 3 wt. %, aphosphorus concentration of less than about 0.5 wt. %, and a potassiumconcentration of from about 1 wt. % to about 3 wt. %.

Aspect 90: The liquid organic fertilizer product of aspect 79,comprising a colloidal suspension.

EXAMPLES Example 1

With reference to the figures, various exemplary aspects of thetreatment methods described herein are detailed below. In one aspect, anexemplary block schematic of the process is illustrated in FIG. 1. Theexemplary process illustrated in FIG. 1 comprises a prep tank into whichchicken manure in the form of, for example, broiler litter and/or layermanure, is added. Water and a 50% aqueous solution of citric acid areadded to adjust the moisture content of the chicken manure to a level ofat least about 80 wt. % and to adjust the pH of the chicken manure to avalue of from about 6 to about 7 to stabilize the waste and capture anyresident ammonia as ammonium citrate.

The mixture is then conveyed to a primary aeration tank, where it isaerated to maintain aerobic conditions. The pH stabilized and aeratedwaste stream is then transferred to a centrifuge, such as, for example,a decanter centrifuge, wherein solids components are separated liquidcomponents. The separated solid components are subsequently pelletizedand dried to a moisture level of less than about 12 wt. %. The separatedliquid components are transferred to the first stage of an aerobicbioreactor, wherein the liquid components are heated and sparged withair for a period of time to promote thermophilic bacteria and tomaintain aerobic conditions. After completion of the first stage of theaerobic bioreactor, all or a portion of the liquid components can betransferred to the second stage of the aerobic bioreactor, whereinfurther heating and aeration are performed for a period of time. Aftercompletion of the second stage of the aerobic bioreactor, all or aportion of the liquid components can be transferred to a sterilizer,wherein the liquid can be heated to kill any pathogens remainingtherein. After sterilization, the liquid components can be transferredto packaging or storage areas, and optionally can have additionalnutrients, such as, organic nitrogen and/or phosphorus nutrients addedthereto.

Example 2

In another aspect, an alternative exemplary block schematic of theprocess is illustrated in FIG. 2. The exemplary process illustrated inFIG. 2 comprises a prep tank into which chicken manure in the form of,for example, broiler litter and/or layer manure, is added. Water and a50% aqueous solution of citric acid are added to adjust the moisturecontent of the chicken manure to a level of at least about 80 wt. % andto adjust the pH of the chicken manure to a value of from about 6 toabout 7 to stabilize the waste and capture any resident ammonia asammonium citrate.

The mixture is then conveyed to a primary aeration tank, where it isaerated to maintain aerobic conditions. The pH stabilized and aeratedwaste stream can then be transferred to the first stage of an aerobicbioreactor, wherein the waste material is heated and sparged with airfor a period of time to promote thermophilic bacteria and to maintainaerobic conditions. After completion of the first stage of the aerobicbioreactor, all or a portion of the waste material from the first stageof the bioreactor can be transferred to the second stage of the aerobicbioreactor, wherein further heating and aeration are performed for aperiod of time. After completion of the second stage of the aerobicbioreactor, all or a portion of the liquid components can be transferredto a centrifuge, such as, for example, a decanter centrifuge, whereinsolids components are separated liquid components. The separated solidcomponents are subsequently pelletized and dried to a moisture level ofless than about 12 wt. %.

The separated liquid components can then be transferred to a sterilizer,wherein the liquid can be heated to kill any pathogens remainingtherein. After sterilization, the liquid components can be transferredto packaging or storage areas, and optionally can have additionalnutrients, such as, organic nitrogen and/or phosphorus nutrients addedthereto.

Example 3

FIG. 3 illustrates a detailed exemplary treatment process. In such anexemplary aspect, bulk waste product containing manure is delivered inbulk 1, generally by a tractor-trailer, dump truck, conveyor truck orthe like, and transferred to a prep tank 110, wherein the waste productis sprayed with water 2 and an acid, such as an aqueous 50% solution ofcitric acid 3. The resulting mixture is transferred using a cavity pump5 to a vibratory screen 6 to separate stones and other undesirablematerials from the mixture. The mixture is then transferred 7 to aprimary aeration tank 120, where the mixture is sparged with air 9,steam 10 is injected to raise the temperature of the mixture to about65° C., and water 8 is optionally added. A recirculation pump 11 canoptionally circulate material within the aeration tank. Gases from theaeration tank, such as, for example, sparged air, can be conveyed 12 toa biofilter 170 before being vented to atmosphere. Solids from theaeration tank can then be conveyed using a progressive cavity pump 13 toa decanter centrifuge 130. Solids separated in the decanter centrifuge130 can then be conveyed 14 to a granulator 135 before being dried andpackaged for use as a solid organic fertilizer 15.

Liquids separated in the decanter centrifuge 130 can be conveyed 16 to afirst stage aerobic bioreactor 140, wherein water 17 can be added andair 19 is sparged. The temperature of the first stage aerobic bioreactorcan be maintained at about 65° C. Optionally, a recirculation pump 18can circulate material in the reactor. After the first stage aerobicbioreactor, the resulting liquid can be passed to a second stage aerobicbioreactor 145, which can also be maintained at a temperature of about65° C. The liquid in the second stage aerobic reactor 145 can be spargedwith air 22. A recirculation pump can also circulate material 23 in thesecond stage bioreactor. Exhaust gases 20, 24 from both the first stageand second stage bioreactors can optionally be directed to anammonia-water receiver 160. The liquid stream from the ammonia-water 160receiver, if used, can then be directed to a base product receiving tank180 or a formulated product receiving tank 185. Additional organicnutrients, such as, for example, organic nitrogen and/or phosphorusnutrients can optionally be added 34,35 to the treated product streamin-line from the ammonia-water receiver, if used, to the formulatedproduct receiving tank, or directly into the formulated productreceiving tank itself.

Treated liquid components from the second stage bioreactor can beconveyed 25 to a sterilizer 150, where steam 27 is used to heat theliquid, which can then be conveyed 29, 30 to a base product receivingtank 180 or a formulated product receiving tank 185. Additional organicnutrients, such as, for example, organic nitrogen and/or phosphorusnutrients can optionally be added 34, 35 to the treated product streamin-line from the ammonia-water receiver, if used, to the formulatedproduct receiving tank, or directly into the formulated productreceiving tank itself.

What is claimed is:
 1. A process for manufacturing an organic fertilizerproduct, the process comprising: a. providing an animal wastecomposition comprising an animal waste, b. contacting the animal wastecomposition with an acid to produce a stabilized animal wastecomposition, c. aerating the animal waste composition, and d. separatinga solid component and a liquid component of the stabilized animal wastecomposition.
 2. The process of claim 1, wherein the animal wastecomposition comprises chicken manure.
 3. The process of claim 1, whereincontacting further comprises adjusting the moisture content of theanimal waste composition to a level from about 80 wt. % to about 98 wt.%.
 4. The process of claim 1, wherein the acid comprises citric acid. 5.The process of claim 1, wherein contacting comprising an addition ofacid sufficient to adjust the pH of the animal waste composition to avalue of from about 4 to about
 7. 6. The process of claim 1, whereincontacting further comprises heating the animal waste composition topromote the growth of mesophilic bacteria.
 7. The process of claim 1,wherein aerating the stabilized animal waste composition comprisessparging with air or oxygen.
 8. The process of claim 1, wherein a pH ofthe stabilized animal waste composition is maintained at a level of fromabout 4 to about 7 during aerating.
 9. The process of claim 1, whereinaerobic conditions are maintained throughout the process.
 10. Theprocess of claim 1, wherein separating comprises separating the solidcomponent and liquid component of the stabilized animal wastecomposition using a decanter centrifuge.
 11. The process of claim 1,wherein separating comprises selectively concentrating one or morenutrients in the solid component, the liquid component, or a fractionthereof.
 12. The process of claim 1, wherein at least about 30 wt. % ofphosphorus present in the stabilized animal waste composition isselectively removed.
 13. The process of claim 1, further comprisingsubjecting the separated liquid component to an autothermal thermophilicaerobic bioreaction.
 14. The process of claim 13, wherein theautothermal thermophilic aerobic bioreaction comprises heating thestabilized separated liquid component to a temperature of at least about45° C.
 15. The process of claim 13, wherein the autothermal thermophilicaerobic bioreaction comprises maintaining aerobic condition and atemperature suitable for the promotion of thermophilic bacteria for aperiod of time.
 16. The process of claim 13, wherein the autothermalthermophilic aerobic bioreaction comprises maintaining a dissolvedoxygen level in the separated liquid component of from about 4 mg/l toabout 6 mg/l.
 17. The process of claim 15, wherein the period of timecomprises from about 1 day to about 18 days.
 18. The process of claim13, wherein the separated liquid component, after the first stage or thesecond stage of the autothermal thermophilic aerobic bioreaction, issubjected to sterilization to kill all or substantially all pathogenspresent therein.
 19. An organic fertilizer product prepared from themethod of claim
 1. 20. The organic fertilizer of claim 19, being freefrom or substantially free from pathogens.